Zero tension system conveyor

ABSTRACT

Zero tension system conveyor. A conveyor belt is driven by at least a portion of the conveyor belt being in continuous contact with a block chain within at least a portion of an overall conveyor belt system. Such a conveyor belt system may be implemented in a spiral configuration such that a relatively small portion of the overall width of the conveyor belt is in contact with the block chain above and/or below the conveyor belt. The static force/weight of the conveyor belt in conjunction with the continuous contact between at least a portion of the conveyor belt and the block chain effectuates the driving of the conveyor belt through the overall conveyor belt system. The block chain is composed of a number of links, at least some of which include a respective hook/protrusion on one side thereof, for being directly engaged by drum bars implemented within a drum assembly.

CROSS REFERENCE TO RELATED PATENTS/PATENT APPLICATIONS

The present U.S. Utility Patent Application claims priority pursuant to35 U.S.C. §120 as a continuation of U.S. Utility application Ser. No.13/670,399, entitled “Zero tension system conveyor,” filed Nov. 6-2012,and scheduled subsequently to be issued as U.S. Pat. No. 9,010,528 onApr. 21, 2015 (as indicated in an ISSUE NOTIFICATION mailed from theUSPTO on Apr. 1, 2015), which claims priority pursuant to 35 U.S.C.§119(e) to U.S. Provisional Application No. 61/556,445, entitled “Zerotension system conveyor,” filed Nov. 7, 2011, both of which are herebyincorporated herein by reference in their entirety and made part of thepresent U.S. Utility Patent Application for all purposes.

BACKGROUND OF THE INVENTION

Technical Field of the Invention

The invention relates generally to conveyor systems; and, moreparticularly, it relates to conveyor systems for moving any of a numberof types of products, articles of manufacture, etc. such as along one ormore conveyor belts.

Description of Related Art

Conveyor systems, such as those that include a conveyor belt, have beenin use and under continual development for many years. The applicationswithin which such conveyor systems may be implemented are varied,including food production, packaging, product assembly, etc. Generallyspeaking, such conveyor systems may be implemented in any of a varietyof different contexts for any of a variety of different purposes.

Within many prior art conveyor systems, the conveyor belt therein isdriven by friction against the drum bars with one or more drivingrollers, against support frames extending from a drive assemblyunderneath the conveyor belt, or in accordance with some otherfrictionally based drive mechanism. For example, considering animplementation of an endless conveyor system (i.e., a conveyor systemhaving a conveyor belt whose ends are attached) is driven by frictionbetween the conveyor belt and the drum bars with one or more rollersthat are physically in contact with the conveyor belt. As may beunderstood with respect to such prior art systems, a great deal oftension must be maintained in the conveyor belt to ensure appropriatecontact between these one or more driving rollers and the conveyor belt,in that, the belt is driven through friction between the drivingcomponents and the conveyor belt itself.

The deficiencies of prior art conveyor systems are many. For example,because of the very high tension that must be maintained in accordancewith the frictional engagement and driving of the conveyor belt, therecan be significant wear and tear on the conveyor belts within suchsystems. For example, in an effort to deal with the wear and tearparticularly introduced by such a frictionally driven system, additionalconsideration must often be made in regards to the interfacing of theconveyor belts to components within the conveyor belt system (e.g.,including employing protective plastic caps, strips, and other materialsin efforts to minimize the rate of degradation of the conveyor belt).

Because of this significant degradation in conveyor belt integrity, itmay be understood that such conveyor belts need to be replaced to ensureappropriate operation of the overall system. During such maintenance,such as the replacement of the conveyor belt within the system, thesystem is clearly inoperable resulting in a great deal of downtime, lossof productivity, increased operating costs, etc. Moreover, in certainapplications, such as those related to food processing and/orproduction, the prior art designs are unfortunately quite susceptible tovarious food products being trapped and caught within various portionsof the overall system, which can compromise sanitation, cleanliness,product quality, etc. (e.g., often-times directly as a result ofadditional considerations that are made in efforts to minimize the rateof degradation of the conveyor belt, including employing protectiveplastic caps, strips, and other materials). To deal with suchdeficiencies, such prior art conveyor systems typically undergo ashutdown and maintenance operation during which, again, the system isclearly inoperable resulting in a great deal of downtime, loss ofproductivity, increased operating costs, etc. The prior art does notpresently provide any solution by which such deficiencies and problemsmay be avoided.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates an embodiment of a conveyor belt system.

FIG. 2 illustrates an embodiment of a conveyor belt system implementedwith separate processing regions.

FIG. 3 illustrates an embodiment of a spiral conveyor belt system.

FIG. 4 illustrates an embodiment of a drum assembly and block chain.

FIG. 5 illustrates an embodiment of a spiral conveyor belt systemincluding a drum assembly and block chain.

FIG. 6 illustrates an embodiment of block chain and conveyor beltin-feed and out-feed with reference to a drum assembly of a spiralconveyor belt system.

FIG. 7, FIG. 8, FIG. 9, FIG. 10, and FIG. 11 illustrate variousembodiments A, B, C, D, and E, respectively, of a block chain andconnected links thereof.

FIG. 12 illustrates an embodiment of compression engagement of aconveyor belt with stacked levels of a block chain.

FIG. 13 illustrates an embodiment of various conveyor belt options.

FIG. 14 illustrates an embodiment of a conveyor belt, includingintegrated support(s), with stacked levels of a block chain.

DETAILED DESCRIPTION OF THE INVENTION

Generally speaking, a novel design and architecture is presented hereinby which a conveyor system may be implemented by employing a directdrive engagement of the conveyor belt through the use of an accompanyingblock chain. Such a block chain may be constructed of any of a number ofselected materials, and is particularly constructed in accordance with apolyethylene type material such as ultrahigh molecular weight (UHMW)plastic in one embodiment. Alternatively, such a block can bereconstructed in accordance with a nonporous plastic, such as a foodgrade nonporous plastic when such a conveyor system is implemented inaccordance with food processing and/or food production applications.Also, as will be understood with respect to various embodiments and/ordiagrams herein, such a block chain as employed herein can be cleanedalong with the primary conveyor belt within the length of the returnportion of the belt path. This allows for the ability to effectuate suchcleaning and maintenance without completely shutting down the system.

Such a novel design and architecture operates by applying little or notension to the conveyor belt itself. That is to say, the conveyor beltis driven through direct engagement by an accompanying block chain asopposed to through frictional engagement of the conveyor belt itselfwith the drum bars themselves. The unique block chain drive systemwithin such a zero tension conveyor system, in accordance with variousaspects, and their equivalents, of the invention, reduces the tensionwithin the conveyor belt to be substantially or approximately near zeroby directly affixing the conveyor belt to a drum assembly via a numberof block chain links. By substantially reducing or eliminating anytension within the conveyor belt, the lifetime of a conveyor beltimplemented within such a zero tension conveyor system may be increasedsignificantly. That is to say, such a block chain drive system withinsuch a zero tension conveyor system eliminates one of the sources ofconveyor belt wear that can occur on the edge of the conveyor beltwithin those systems operating in accordance with frictional engagementbetween a conveyor belt and the drum bars. Oftentimes, when a conveyorbelt needs to be replaced, it is because of deleterious wear in severallocations on the conveyor belt (e.g., such as at the outer links orouter edge of the conveyor belt such as from running against stainlesssteel bars where caps, such as protective plastic caps, strips, andother materials, are missing or degraded, sometimes significantly, dueto wear and tear, etc.).

Such a block chain drive system in accordance with various aspects, andtheir equivalents, of the invention can also provide for a significantimprovement in overall cleanliness, sanitation, etc. for those conveyorsystems implemented in accordance with food processing and/or foodproduction applications. Because of such improvements, there issignificantly reduced downtime required for maintaining, cleaning, etc.a conveyor system as described herein.

As may also be understood in accordance with the various embodimentsand/or diagrams herein, a zero tension system conveyor implemented inaccordance with various aspects, and their equivalents, of the inventionmay be implemented in a very low profile design having a very smallfootprint while obviating the need for extremely frequent maintenanceand while obviating many of the sanitation issues associated with othertypes of conveyor systems. Also, the use of such a block chain drivesystem allows for a relatively small conveyor belt radius therebyallowing for a relatively small footprint. In addition, the use of sucha block chain drive system allows for direct engagement with a drumassembly (e.g., such as by using drum bars associated therewith) therebyforming a direct drive from the drum assembly to the conveyor belt. Suchdrum bars may be constructed of any of a number of selected materials,and is particularly constructed in accordance with stainless steel inone embodiment.

This direct engagement of the drum assembly to the conveyor beltsubstantially reduces or eliminates any tension that is required againstthe drum assembly to drive the conveyor belt (e.g., the driving of theconveyor belt is effectuated via direct engagement of the block chain todrum bars of the drum assembly as opposed to the conveyor belt beingdriven in accordance with a frictional engagement). As may beunderstood, the substantial reduction or elimination of friction beingrequired to drive the conveyor belt allows for a significant reductionin the horsepower required to drive the overall conveyor belt system.For example, the electricity, energy, horsepower, required to sustainmotion of the conveyor belt in accordance with a substantially reducedor eliminated tension conveyor belt system as described herein isgreatly reduced through direct drive. For example, as will be seen inaccordance with the direct mechanical engagement between respectivelinks of a block chain with drum bars of a drum assembly, there is noinherent energy loss such as that which may be associated with aslipping friction drive in other systems. A lower horsepower motor withan associated smaller transmission may be used in driving the drumassembly of such a conveyor belt system as described herein. Moreover,additional power consumption savings may be achieved from theunrestricted airflow options that can be used to optimize or maximizethe respective energy exchange rates within the system. For example, asan effective heat transfer rate is improved through more efficientairflow, additional operational process savings may be achieved.

FIG. 1 illustrates an embodiment 100 of a conveyor belt system. Asdescribed elsewhere herein, a conveyor belt system may be employed forany of a number of purposes in any of a number of applications. Forexample, such a conveyor belt system may be employed for moving variousproducts from one point to another. Such movement may be associated withmanufacturing of one or more articles or components, production of oneor more articles or components (including food products), etc. Forexample, with reference to food processing and/or food production, sucha conveyor belt system may be utilized in applications associated withfreezers, proofers, ambient, drying, airflow, and cooking applications.As will be understood in accordance with the various diagrams and/orembodiments herein, with respect to airflow applications, given the opendrum construction and open conveyor belt design, such as in accordancewith (though not limited to) spiral conveyor systems, provided herein inaccordance with a substantially tension reduced or tension eliminatedconveyor belt system, any of a number of airflow implementations may beeffectuated including vertical and/or horizontal airflow across productbeing conveyed on the conveyor belt, including, vertical up, verticaldown, dual air vertical, dual impingement, horizontal, dual horizontal,high/low horizontal, etc.

The embodiment 100 shows very generally how a conveyor belt system maybe viewed as including an endless conveyor belt, such that therespective ends of the conveyor belt are connected thereby forming acontinuous and endless loop. The conveyor belt may pass by and around anumber of rollers, including end rollers, before repeating itsrespective path. As may be understood, depending upon the direction ofmovement of the conveyor belt, a forward pass of the belt and a returnpath of the belt will be oppositely situated with respect to each other.It is also noted that such conveyor belt systems may be implemented inany of a variety of configurations, including spiral implementedconfigurations such that certain portions of the conveyor belt passextend helically around a drum assembly such that products may beconveyed up or down around that drum assembly.

However, it is noted that the various means by which a conveyor belt maybe driven within such a conveyor belt system in accordance with usingdirect engagement by a block chain as described herein may be extendedto any desired configuration of conveyor belt system (e.g., includingthose which are not helically based).

In addition, it is noted that while certain embodiments envision movingproduct along the path of the conveyor belt in only one direction,alternative embodiments may include the capability to drive the conveyorbelt in more than one direction. For example, considering a conveyorbelt as an accumulating conveyor, such a conveyor belt may be operativeto convey a product in one direction during a first time or time period,and operative to convey that same product, or other product, in anotherdirection during a second time or time period. Certain embodiments mayinclude a forward and reverse direction for conveying product along thepath of the conveyor belt. In addition, it is noted that multiplerespective conveyor systems may interact cooperatively such that morethan a singular pathway exists, and certain portions of conveyors may beoperative in forward and backward directions, while other portions ofconveyors may be operative in only one of the forward or backwarddirections, etc. Generally speaking, any desired combination of variousconveyors, in any desired configuration, may be implemented inaccordance with any one or more of the various aspects, embodiments,and/or their equivalents, of the invention.

FIG. 2 illustrates an embodiment 200 of a conveyor belt systemimplemented with separate processing regions. This diagram shows howdifferent respective portions of the conveyor belt may undergo differentrespective processing. For example, as may be understood in accordancewith certain manufacturing processes, different operational steps may beperformed on a given article of manufacture at different times duringthe entire manufacturing process. With respect to food processing andproduction, different operational steps may be performed in accordancewith generating an end food product. It is of course noted that a givenproduct may undergo modification during one or more of the respectiveoperational processes applied thereto, in that, a product may be firstlymodified in accordance with the first processing region, secondlymodified in accordance with the second processing region, etc. As may beunderstood, during such operations, the product being conveyed via theconveyor belt system may undergo modification and/or transformationduring its respective passage through the conveyor belt system.

In accordance with performing different respective processing operationson respective products (e.g., whether they be articles of manufacture,food components, etc.), different environmental considerations andconstraints may be particularly associated with each respectiveprocessing region. For example, any two respective processing regionsmay have as few as one or as many as all different respectivecharacteristics, such as, temperature, humidity, moisture, airflow,pressure (e.g., such as environmental/air pressure within a givenregion), heating, cooling, drying, freezing, addition of one or morecomponents, modification of size (e.g., such as cutting or reducing to aspecified or desired size), packaging, etc. That is to say, eachrespective processing region may be particularly tailored to performingany one or more of the total operational steps employed in creating anend product. For example, within a food processing and productionimplementation, a first processing region may be associated with mixinga number of components together, while a second processing region may beassociated with cooking the resultant of mixed components, while a thirdprocessing region may be associated with cooling the cooked resultant,while a fourth processing region may be associated with packaging thefinal resultant, etc. Generally, it may be understood that differentrespective processing regions may be specifically suited and tailoredfor performing different operations and the respective environmentalconsiderations and constraints within those different respective regionsmay be varied.

Again, as also described with respect other embodiments, differentrespective directional movement of product along any one or moreconveyors may be made, including both forward and backward movement ofproduct at different respective times or time periods, such as inaccordance with an accumulating conveyor.

FIG. 3 illustrates an embodiment 300 of spiral conveyor belt system. Asdescribed elsewhere herein, various aspects, and their equivalents, ofthe invention may be generally applied to any desired conveyor beltsystem having any particular type of configuration or architecture, oneparticular embodiment is directed towards a spiral conveyor system inwhich a product moves helically around a drum assembly either upward ordownward. For example, a conveyor belt is implemented such that theconveyor belt encircles a drum assembly in a spiral configuration suchthat respective products are conveyed either up or down by the conveyorbelt. Operations performed on the products may be varied with respect todifferent respective tiers of the overall spiral structure encirclingthe drum assembly.

As can be seen in the left hand side of the diagram, the differentrespective tiers or levels of the spiral architectural portion of theconveyor belt system will generally have some tilt associated therewithas the conveyor belt helically winds around the drum assembly eitherupward or downward. As can be seen in the right-hand side of thediagram, considering one particular level of the spiral architecture,the conveyor belt may be viewed as subsuming or overriding itself fromthe top view perspective because of the helical passage of the conveyorbelt upward or downward around the drum assembly.

Generally, the spiral conveyor system may be understood as movingproduct around such a drum assembly in a spiral configuration either toelevate or lower the product in accordance with each respective rotationaround the drum assembly. The use of a vertical spiral pattern may allowfor extending and controlling the length of time that a product is onthe conveyor belt and held within the defined footprint. In accordancewith certain food processing, production, and/or packaging applications,the use of a limited footprint allows for environmental control (e.g.,by implementing the spiral architecture within an enclosed andenvironmentally controllable environment) to control any of a number ofconditions including temperature, humidity, moisture, airflow, pressure,heating, cooling, drying, freezing, etc.

FIG. 4 illustrates an embodiment 400 of a drum assembly and block chain.As can be seen with respect to this diagram, a conveyor belt passesaround a drum assembly such that a block chain also passing around thatdrum assembly engages each respective helical pass of the conveyor beltabove and below the conveyor belt in accordance with a clamping forcebetween respective stacking points in a helical structure. For example,from certain perspectives, the conveyor belt and the block chain may beviewed as both spiraling around the drum assembly, yet the configurationof the block chain and the conveyor belt may be viewed as being 90° withrespect to each other. That is to say, the block chain may be viewed asengaging a number of drum bars (e.g., which are pictorially illustratedwith respect to other diagrams) on one side (e.g., on the backside ofthe block chain), while the block chain may also be viewed as engaging aportion of the conveyor belt above and below in accordance with aclamping force between respective stacking points in a helicalstructure. For example, as the conveyor belt spirals around the drumassembly in the helical fashion, the block chain, while being engagedand driven by the drum bars of the drum assembly, is in contact with theconveyor belt. As may be seen with the diagram, an alternating patternmay be viewed with respect to the block chain and the conveyor belt withrespect to the various tiers of the helical structure associated withthe drum assembly. For example, considering the block chain and conveyorbelt as propagating upward through the helical structure, thealternating pattern between block chain and conveyor belt may be viewedas beginning with block chain, then conveyor belt, then block chain, andso on until at the top of the helical structure, the block chain is thefinal resulting element. Because of the inherent static force/weight ofthe conveyor belt, there is effectuated a clamping force between therespective stacking points of where the block chain meets with theconveyor belt within the helical structure.

That is to say, the inherent static force/weight of the conveyor belt,in conjunction with the layered and alternating implementation of theblock chain/conveyor belt configuration around the drum assembly, theinherent and continuous contact between the block chain and even a verysmall portion of the conveyor belt sufficiently engages the conveyorbelt (e.g., clamping force) in driving the conveyor belt through theentire spiral conveyor belt system.

As may be seen with respect to this diagram, both the block chain andthe conveyor belt may also pass through any of a number of additionalpathways within the overall system. If desired in some embodiments, boththe block chain and the conveyor belt may take a relatively similar paththroughout the overall system. However, in other embodiments, the blockchain and the conveyor belt may take entirely different paths throughthe overall system outside of the drum assembly portion thereof. That isto say, the interaction between the block chain and the conveyor beltwithin the helical structure associated with the drum assembly may beviewed as that component which effectuates the driving of the conveyorbelt through the entire spiral conveyor belt system, and it is notnecessary that the block chain follows a similar path through the entirespiral conveyor belt system as made by the conveyor belt itself.

Within this diagram, it may be seen that a conveyor belt end roller anda block chain end roller are axially aligned with one another (e.g.,which may be viewed as designer choice), but alternative embodimentsneed not necessarily have such a feature. For example, in such anembodiment such that the block chain and the conveyor belt share atleast one axially aligned end roller, roller, component, etc., this mayrequire that the block chain undergo a 90° orientation shift whentransitioning from the drum assembly portion of the overall spiralconveyor belt system to other portions thereof. That is to say,considering the block chain as having a first dimension being relativelywider than another dimension (e.g., being X″×Y″ respectively indimension, such that X is larger than Y, without considering the overalllength of the block chain), then the relatively wider dimension may beselected for engaging the drum bars of the drum assembly on one side ofthe block chain.

FIG. 5 illustrates an embodiment 500 of a spiral conveyor belt systemincluding a drum assembly and block chain. This diagram pictoriallyillustrates the respective drum bars of the drum assembly as directlyengaging at least some of the respective links of the block chain. Also,for ease of illustration for the reader, the respective tiers of thehelical pathway encompassing the drum assembly are shown as beinggenerally level with respect to the reference of the diagram, though thereader will of course understand that in an actual helical architecture,the respective tiers of the conveyor belt and block chain will beactually rising or falling in elevation as they propagate around thedrum assembly. Also, each respective link of the block chain is notpictorially illustrated within each respective tier within the drumassembly portion for ease of illustration for the reader (e.g., to allowfor illustration of the drum bars within the drum assembly).

At the top left portion of the diagram, a feature associated with atleast some of the respective links of the block chain corresponds to ahook or protrusion on the backside thereof for directly engaging thedrum bars which extend generally vertically within the drum assembly(e.g., for locking onto the drum bars to assist in driving the blockchain in at least one given direction). As also understood with respectto other embodiments, at least one embodiment may include one or morehooks or protrusions on one or more of the links or segments of theblock chain to assist in directly engaging with the drum bars of thedrum assembly to assist driving the block chain in one or moredirections (e.g., such that a given conveyor belt may be driven at leastforward and backward). Also, it is noted that each and every block chainlink or segment need not necessarily include a corresponding hook orprotrusion thereon. At least one embodiment may include a correspondinghook or protrusion on each respective block chain link or segment. Atleast one additional embodiment may include a corresponding hook orprotrusion on fewer than each respective block chain link or segment(e.g., generally less than all, every other block chain link or segment,every Nth block chain link or segment [where N is any desired integer],or using some other pattern such as a non-uniform and/or non-repeatingpattern, etc.).

As can be seen within this diagram as well, the respective drum bars maygenerally have a backwards leaning slope to assist in effectuating thehelical and spiral propagation of the block chain and conveyor beltthrough the drum assembly portion of the overall spiral conveyor beltsystem. For example, rather than having a 90° vertical attachment, therespective drum bars have this backwards leaning slope to assist inlifting the block chain with each respective revolution of the drumassembly. The respective links of the block chain, as being inmechanical engagement using the respective hooks/protrusions on thebackside thereof, glide upwards on the drum bars to form the next tierlevel within the spiral architecture. The drum bars may be particularlydesigned with a selected backwards tilt angle such as to allow therespective links of the block chain to release their grip and move orslide upwards or downwards with a relatively minimal sliding friction.

As referenced elsewhere herein, multiple respective stacking points maybe viewed as existing through the alternating and stacked structure ofthe block chain and the conveyor belt. For example, the block chain,which may be implemented in accordance with any of a number ofrespective embodiments, several of which are described elsewhere herein,helically encompasses the drum assembly such that a portion of theconveyor belt is in contact with the block chain within the drumassembly. For example, it is noted that only a relatively small portionof the conveyor belt need be in contact with the block chain. Forexample, considering a conveyor belt having a width of Z″, then only arelatively small percentage of that width (e.g., 5%, 10%, etc.) need bein contact with the block chain within the drum assembly portion of theoverall spiral conveyor belt system. It is also noted that therelatively inner portion of the conveyor belt, namely, that portionwhich is relatively closer to the drum assembly, is that portion of theconveyor belt which is in contact with the block chain. The remainder ofthe conveyor belt (e.g., the entire remainder of the conveyor beltexcept for that relatively small percentage thereof that comes intocontact with the block chain) may be supported in any of a number ofways including using one or more rollers, one or more static supportssuch as a fixed helix rail [e.g., outer belt support] attached to thesupport structure surrounding the conveyor belt path, etc. For example,as may be understood with respect to this embodiment and/or otherdiagrams and/or embodiments herein, only the inner edge of the conveyorbelt is engaged (e.g., clamping force between respective stacking pointsin a helical structure) with the block chain within the spiralarchitecture. The spiral conveyor column assembly forms an overarchingsupport structure around the outside of the drum assembly and therespective conveyor belt tiers (e.g., a helical stacked structure). Thissupport structure secures the top center bearing hub of the drum shaftand each respective leg thereof may be implemented to provide multiplesupports for the outer edge of the conveyor belt at each respective tierlevel therein.

A number of observations may be made with respect to the implementationof directly engaging the conveyor belt by use of a block chain grabbingthe conveyor belt on both its respective top and bottom surfaces. Forexample, because the static force/weight of the belt is in continuouscontact with the block chain throughout the drum assembly portion of theoverall spiral conveyor belt system, there is little to no tension orstress incurred by the conveyor belt. From certain perspectives, theinteraction between the block chain and the conveyor belt may be viewedas being a very distributed interaction continuously throughout the drumassembly such that there are little or no outline stress points as maybe applied to the conveyor belt. Because the conveyor belt is incontinual contact with the block chain throughout the drum assembly,there will be very little if any stress applied to the conveyor beltwhich may potentially degrade the quality of the conveyor belt itself.As such, because there is little if any stress applied to the conveyorbelt, the relative lifetime of the conveyor belt implemented within sucha zero tension system conveyor, such as within a spiral configuration asdescribed with reference herein, may be extended significantly incomparison to prior art conveyor systems which drive the conveyor beltvia frictional engagement. Again, as may be understood with reference toFIG. 5, the conveyor belt and the block chain are in continuous contactthrough the entirety of the drum assembly portion of the overall spiralconveyor belt system. As such, there are no localized and highlystressful contact points between the conveyor belt and the block chain.

With respect to the design of the drum employed within such a drumassembly, a drum may be employed that rotates about its axis (e.g.,extending vertically through the center of the drum assembly). As may beunderstood with respect to the substantially reduced or zero tensionoperation as provided in accordance with various aspects, and theirequivalents, of the invention, a substantially reduced drive motor maybe employed in driving the drum assembly including the respective drumbars providing direct engagement to the block chain. Moreover, therespective drum bars are operative to engage the block chain with directmechanical force which in turn directly engages the inner edge of theconveyor belt. Rotation of the conveyor belt is not dependent on aprecise amount of friction with the drum assembly. Also, rather thanemploying flat bars designed to distribute compression forces from thebelt tension, the respective drum bars within the drum assembly hereinare cylindrical. However, it is noted that alternatively shaped drumbars may be employed (e.g., square, rectangular, triangular, flat bar,etc.) without departing from the scope and spirit of the invention. Eachrespective drum bar may be secured in an extended position such that theleading edge thereof is obstructed by supports to allow the respectivehooks/protrusions of the block chain to move axially against the drum asit ascends the length of a given drum bar.

FIG. 6 illustrates an embodiment 600 of block chain and conveyor beltin-feed and out-feed with reference to a drum assembly of a spiralconveyor belt system. This diagram pictorially illustrates a block chainand conveyor belt entering into and exiting from a drum assembly. Ablock chain has a mechanical subassembly at the in-feed of the drumassembly to join the conveyor belt, and the discharge section of thespiral has a mechanical subassembly to divide the block chain and theconveyor belt. Again, by directly connecting the conveyor belt to thedrum assembly using the block chain, the conveyor belt is driven withsubstantially reduced or zero tension thereby allowing for a greatlyextended conveyor belt life (e.g., and also substantially extending thetime periods between maintenance and replacement of the conveyor beltwithin such systems). This particular diagram shows the block chain andconveyor belt entering near the bottom of the drum assembly and exitingnear the top of the drum assembly, though it is noted that the conversemay be desirable within certain embodiments (e.g., entering near the topof the drum assembly and exiting near the bottom of the drum assembly).Also, it is noted that while this particular diagram also shows acounterclockwise drum rotation, the converse of a clockwise drumrotation may be desirable within other embodiments without departingfrom the scope and spirit of the invention.

As may be understood with respect to the helical and spiral architectureof the respective paths of the block chain and conveyor belt within thedrum assembly portion, considering the implementation where the blockchain and conveyor belt are entering near the bottom of the drumassembly and exiting near the top of the drum assembly, the conveyorbelt and block chain may be viewed as coming into the drum assembly andthen spiraling around in a helical fashion towards the top of the drumassembly, and then exiting from the drum assembly upon reaching the topthereof.

As may be seen with respect to this diagram, there is a portion ofoverlap between the conveyor belt and the block chain. As the blockchain is directly engaged with the respective drum bars of the drumassembly, the block chain also overlaps with and is in continuouscontact with the conveyor belt within the drum assembly portion.Moreover, as can be seen pictorially within this diagram, only arelatively small portion of the conveyor belt need be in contact withthe block chain. The remaining portion of the conveyor belt may besupported in any particular desired way, including using one or morerollers, one or more static supports such as a fixed helix rail [e.g.,outer belt support] attached to the support structure surrounding theconveyor belt path, etc. Also, while this diagram pictoriallyillustrates the conveyor belt extending completely across the entirewidth of the block chain in the overlap region, it is noted that certainembodiments may include one or more means by which the conveyor beltwill be kept from coming into contact with the drum bars of the drumassembly.

In addition, within certain embodiments, a belt compression device maybe implemented at the intake and/or outtake of the conveyor belt and/orblock chain to/from the drum assembly. That is to say, such a beltcompression device may be implemented to adjust the particular tensionof the conveyor belt and/or block chain as they engage with the drumassembly. For example, by providing for a means by which the tension ofthe conveyor belt and/or block chain may be adjusted (e.g., adaptivelyincreased or decreased), deleterious effects such as an inchworm effectof the conveyor belt may be avoided. Moreover, the use of such a beltcompression device may provide a means by which a substantially orapproximately same tension level is made at both the inner edge of theconveyor belt being in mechanical engagement with the block chain aswell as the outer edge of the conveyor belt which may be supported usingone or more rollers, one or more static supports such as a fixed helixrail (e.g., outer belt support) attached to the support structuresurrounding the conveyor belt path, etc. Generally speaking, such a beltcompression device may be implemented to ensure that the outer edge ofthe conveyor belt may be relatively expanded while the inner edge of theconveyor belt may be relatively collapsed. The use of such a beltcompression device implemented at the intake and/or outtake of theconveyor belt and/or block chain to/from the drum assembly may assist inthe reduction of product jams within the overall conveyor belt system.

Again, as also described with respect other embodiments, differentrespective directional movement of product along any one or moreconveyors may be made, including both forward and backward movement ofproduct at different respective times or time periods, such as inaccordance with an accumulating conveyor. For example, considering theclockwise and counterclockwise rotation by which the drum assembly mayrotate, movement of the conveyor in more than one direction may beachieved. Referring again to at least FIG. 5, it is noted that anappropriately designed hook or protrusion made be employed to allow formechanical engagement with the drum bars regardless of which particulardirection the drum assembly is being rotated or driven. For example,certain embodiments may include more than one respective hook orprotrusion per block chain segment to effectuate being driven in morethan one direction, while other embodiments may include a singular hookor protrusion per block chain segment such that that singular hook orprotrusion on a given block chain segment allows for the drum assemblyto be driven in more than one direction.

FIG. 7, FIG. 8, FIG. 9, FIG. 10, and FIG. 11 illustrate variousembodiments A, B, C, D, and E (700, 800, 900, 1000, and 1100,respectively), of a block chain and connected links thereof.

As described elsewhere herein, a conveyor belt, which may be viewed asbeing continuous or endless in design, passes through a conveyor beltsystem through direct engagement as provided by a block chain. That isto say, instead of being driven through frictional engagement of thedrum bars with one or more drive rollers being in direct contact with aconveyor belt, a block chain is implemented as to engage directly theconveyor belt. For example, in one preferred embodiment related to aspiral conveyor system, a rotating drum assembly includes a number ofdrum bars for exerting energy to respective links within a block chainto effectuate the driving and movement of the conveyor belt. As will beseen with respect to other embodiments and/or diagrams herein as well,only a relatively small portion of the conveyor belt comes into physicalcontact with the block chain, in that, a clamping force betweenrespective stacking points of a spiral conveyor system (e.g.particularly around a drum assembly) serve as the mechanism for clampingonto the conveyor belt, such that there is very little, if any, frictionrequired to propel and move the conveyor belt through the spiralconveyor system. By using such a configuration as described herein, thestatic force/weight of the conveyor belt being in respective contactbetween the various stacking points of the spiral conveyor system issufficient and adequate to effectuate direct engagement of the conveyorbelt. Moreover, it is noted that any of a variety of types of blockchains, having different respective types of chain links, may beemployed within such a spiral conveyor system.

Referring to the embodiment A, shown by reference numeral 700 of FIG. 7,a number of respective links of a block chain are connected together.Each respective length of the block chain may be connected using pins(e.g., constructed with stainless steel) such that each respective pincan extend through at least one portion of a first link and at least oneportion of a second link. On one side of the block chain, at least someof the respective links include a hook/protrusion for engaging the drumbars on a drum assembly (e.g., such as may be implemented within thespiral conveyor system). In certain embodiments, each respective link ofthe block chain includes a respective hook/protrusion for engaging drumbars; in other embodiments, one or more links need not necessarilyinclude a hook/protrusion thereon, so long as an acceptable number oflinks within the block chain do in fact include such hooks/protrusionsfor effectuating direct engagement with the drum bars.

As the block chain comes into contact with the drum bars of the drumassembly, the respective hooks/protrusions on the backside of at leastsome of the links of the block chain are directly engaged. As may alsobe understood with respect to other diagrams and/or embodiments herein,the block chain is in continuous contact with at least a portion of theconveyor belt throughout the drum assembly portion of the overall spiralconveyor system.

With respect to this particular embodiment of a block chain and therespective links thereof, a respective link of the block chain may beviewed as having four respective protrusions (e.g., three of which areassociated with inter-coupling or interconnecting the respective linksof the block chain through the use of pins, and one of which includes ahook/protrusion for directly engaging drum bars of the drum assembly).

Within this embodiment as well as others corresponding to a block chain,it is noted that the respective holes through the center or middle hingetab of a given length of the block chain may be constructed as havingdual tapered sides thereby allowing consecutive links of the block chainto twist slightly in addition to rotate around the hinge pin. Within alimited length of the block chain, sufficient cumulative twisting may beeffectuated to allow the conveyor motion of the block chain to move overrollers placed at opposing 90° angles. In one embodiment, amultidirectional tapered hole in the center tab may be employed suchthat the span of consecutive links of the block chain can twist tofollow any desired route through the overall conveyor system.

Also, in addition to the respective hole through the middle hinge tab ofa given link the block chain having all sides tapered outwards from thecenter, the hole may be elongated. Such an elongated hole that providesa slot for the hinge pin to slightly move fore and aft such that alimited capture length of the block chain can be compressed. In turn,this linear compression will allow for the prescribed cumulative lengthof the block chain to be shortened sufficiently to push the respectivehooks/protrusions on the backside of at least some of the links of theblock chain in front of the respective drum bars. Relaxing thecompression may then engage the hook/protrusion around the drum barthereby effectuating the direct drive.

As may also be understood with reference to FIG. 5, among others, anumber of respective edge blocks (e.g., such as associated with therespective wraps of the block chain around the drum assembly) may bereferred to as stacking blocks. As the block chain wraps around the drumassembly a subsequent row of blocks is aligned on top of the conveyorbelt which begins the alternating stack. This alternating stackingprocess occurs with each respective revolution around the drum assemblycontinues from the base of the drum cylinder vertically until it reachesthe top of the drum bar (or in an alternative embodiment, starting fromthe top, continues from the top of the drum cylinder downward verticallyuntil it reaches the bottom of the number). The overall height of theserespective edge blocks determines the respective tier height spacingwithin the spiral assembly.

Referring to the embodiment B, shown by reference numeral 800 of FIG. 8,this embodiment B has some similarities to the previous embodiment A,with at least one difference being that the pins that are employed forinter-coupling or interconnecting the respective links of the blockchain and/or downward extend to provide a means by which the conveyorbelt will be kept from touching the drum bars. For example, theseextended pins may serve as a means by which the conveyor belt will bekept from coming into contact with the drum bars as the block chain andthe conveyor belt propagates through the drum assembly. As may beunderstood with respect to this embodiment as well as others, ensuringthat the conveyor belt does not come into contact with the drum bars cansubstantially reduce or eliminate the possibility of transference ofcontamination from the drum bars to any product on the conveyor belt. Ifdesired, the pins may be implemented in an alternating fashion such thatthe pin of one inter-coupling or interconnection between two respectivelinks of the block chain extends upward, and the next pin of a nextinter-coupling or interconnection between two respective links of theblock chain extends downward, etc. in an alternating fashion. As such,the upward and/or downward extending pin portions will hopefully notcome into contact with one another within the respective tiers of thedrum assembly.

Referring to the embodiment C, shown by reference numeral 900 of FIG. 9,this embodiment C also has some similarities with the previousembodiment A, with at least one difference being that one or more tabsmay be implemented on at least some of the respective links of the blockchain. For example, such tabs, which may be viewed as being recessedfrom the edge of the top and/or bottom of a given link of the blockchain, and implemented relatively closer to the hook/protrusion side ofthe block chain, may serve as a means by which the conveyor belt will bekept from coming into contact with the drum bars as the block chain andthe conveyor belt propagate through the drum assembly. If desired incertain embodiments, tabs may be implemented within an alternatingmanner such that a respective tab occurs every other link of the blockchain on the top side of the block chain and such that a tab occurs inan alternating manner every other link of the block chain on the bottomside of the block chain. For example, analogously as described abovewith respect to embodiment B, by alternating tabs extending upward anddownward with respect to various links of the block chain, those tabportions will hopefully not come into contact with one another withinthe respective tiers of the drum assembly.

With respect to this particular embodiment of a block chain and therespective links thereof, a respective link of the block chain may beviewed as having five (if only one tab is included on a given blockchain link) or six respective protrusions (if two tabs are included on agiven block chain link).

Referring to the embodiment D, shown by reference numeral 1000 of FIG.10, this embodiment D also has some similarities with the previousembodiment C, with at least one difference being that respective tabsimplemented on at least some of the respective links of the block chainare appropriately offset with respect to one another at the top and thebottom of a given length of the block chain. For example, suchconsideration may be viewed as ensuring that such tab portions willhopefully not come into contact with one another within the respectivetiers of the drum assembly.

With respect to this particular embodiment of a block chain and therespective links thereof, a respective link of the block chain may beviewed as having six respective protrusions (two tabs are included on agiven block chain link).

Referring to the embodiment E, shown by reference numeral 1100 of FIG.11, this embodiment E includes individual block chain segments that haveboth a hook and a recess. When forming a helical stacked structure, suchas around the drum assembly that includes a plurality of drum bars, therecesses of respective block chain segments will form an interface intowhich a lengthwise edge of the conveyor belt may couple. For example,considering a helical stacked structure formed by alternately andvertically stacked wraps of the block chain and the conveyor belt, theconveyor belt may be viewed as not only being held in compressionbetween respective portions of the block chain in the helical stackedstructure, but the conveyor belt may be viewed as also being held inmechanical engagement with a structure formed by the stacked segments ofthe block chain. As may be understood with respect to the recesses shownwithin this diagram, a dovetail shape or dovetail form type receiverwill be created between respective stacked segments of the block chain.Of course, any desired shape or form of receiver may be employed indifferent embodiments.

Alternatively, as will be described with respect to other embodimentsherein, instead of forming such a shape or form in between therespective stacked segments of the block chain, any individual blockchain segments may include a shape or form to receive a lengthwise edgeof the conveyor belt. In addition, it is also noted that a lengthwiseedge of the conveyor belt may similarly be formed, fabricated, orconstructed so that it interacts complementary with this shape or formof a receiver associated with the block chain, whether or not thatreceiver shape or form is formed by successively stacked portions of theblock chain or within receiver shapes or forms included withinrespective block chain segments.

Generally speaking, a lengthwise edge of the conveyor belt may be viewedas having a form or shape that interacts complementary with a receivershape or form associated with the block chain, again, whether or notthat receiver shape or form is formed by successively stacked portionsof the block chain or within receiver shapes or forms included withinrespective block chain segments. For example, such interaction may beviewed as a male and female interface, such that the lengthwise edge ofthe conveyor belt interfaces with such a shape or form associated withthe block chain complementarily.

In addition, as may be understood with respect to this diagram, morethan one respective tab may be included above and/or below respectiveblock chain segments so as to prevent the conveyor belt from coming intophysical contact with the drum bars of the drum assembly.

FIG. 12 illustrates an embodiment 1200 of compression engagement of aconveyor belt with stacked levels of a block chain. As may be seen withrespect to this diagram, a conveyor belt may be viewed as being held incompression between respective and successive portions of the blockchain within a helical stacked structure, such as around a drumassembly. It is noted that the particular degree of compression providedby the interaction of the stacking block chain in the conveyor belt maybe of any desired degree of compression. For example, such compressionmay be such as to prevent any slippage of the conveyor belt within thesystem, and particularly when interacting with the block chain inconjunction with the drum assembly. Alternatively, such compression maybe to allow slippage of the conveyor belt, to any desired degree, wheninteracting with the block chain in conjunction with the drum assembly.

Also, it is noted that any desired thickness of conveyor belt may beemployed (e.g., as pictorially illustrated in FIG. 12). For example, atleast one embodiment includes a conveyor belt thickness of approximately0.590 inches. However, it is noted that any desired conveyor beltthickness may be employed as desired in various embodiments.

FIG. 13 illustrates an embodiment 1300 of various conveyor belt options.As may be understood with respect to this diagram, any of a number offorms or shapes of a lengthwise edge of the conveyor belt may allow formechanical interaction with a complementary form or shape formed eitherby successive portions of the block chain in the helical stackedstructure (e.g., composed of alternatively and vertically stacked wrapsof the block chain in the conveyor belt) or with a complementary form orshape included within respective block chain segments. It is noted thatsuch embodiments that include a complementary form or shape includedwithin respective block chain segments may include the receiver of agiven shape or form anywhere along the vertical span of a given blockchain segment or link.

For example, considering the implementation on the left hand side of thediagram, the lengthwise edge of the conveyor belt may be viewed ashaving a dovetail type shape, and a complementary dovetail receivershape may be formed by the successive portions of the block chain of thehelical stacked structure (e.g., composed of alternatively andvertically stacked wraps of the block chain in the conveyor belt).

Considering the implementation in the middle of the diagram, thelengthwise edge of the conveyor belt may be viewed as having a tabextending such that there are at least two respective portions of theedge of the conveyor belt that are held in compression between thesuccessive portions of the block chain of the helical stacked structure.If desired, the degree of compression of both of these respectiveportions may be the same in certain embodiments, or they may bedifferent.

Considering the implementation on the right hand side of the diagram,the lengthwise edge of the conveyor belt also may be viewed as having atab extending outward; however, with respect to this particularimplementation, the receiver shape or form is instead included withinthe respective chain link segments or links as opposed to being formedby the interaction of successive portions of the block chain of thehelical stacked structure.

Again, it is noted that any desired one or more spacers, or otherappropriately functional structures, may be included within one or moreblock chain segments so as to control or limit compression on theconveyor belt to any desired degree. For example, appropriatelyimplemented compression may serve to allow or to prevent slippage of theconveyor belt when interacting with the block chain in conjunction withthe drum assembly.

FIG. 14 illustrates an embodiment 1400 of a conveyor belt, includingintegrated support(s), with stacked levels of a block chain. As may beunderstood with respect to this diagram, the conveyor belt itselfincludes an integrated support along at least a portion of one of thelengthwise edges of the conveyor belt. This lengthwise edge may beviewed as being opposite from the lengthwise edge of the conveyor beltthat is operative to be interacting with the block chain in conjunctionwith the drum assembly. In one embodiment, the conveyor belt may beimplemented as an outer edge self-supporting belt (e.g., where theconveyor belt is driven using an inner lengthwise edge). Alternatively,the conveyor belt may be implemented as an inner edge self-supportingbelt (e.g., where the conveyor belt is driven using an outer lengthwiseedge in such an alternative embodiment). Generally speaking, suchsupport(s) may be located anywhere along the conveyor belt (e.g., notrestricted solely to a lengthwise edge). For example, some embodimentsmay include such support(s) more centrally located as opposed to onlyalong one of the lengthwise edges (e.g., generally anywhere along a flatportion of the conveyor belt to provide support for another portion ofthe conveyor belt above and/or below the location of the support(s),including on a top and/or bottom side of the conveyor belt to providesupport above or below).

As may be understood with respect to this diagram, such animplementation obviates the need for any supports of the conveyor beltwhen interacting with the block chain in conjunction with the drumassembly. For example, given that such support is integrated with theconveyor belt itself, there is no need for additional supports along thewidth of the conveyor belt to ensure stabilization of the conveyor beltwhen interacting with the block chain in conjunction with the drumassembly. Such an implementation may be viewed as a self-supportingsystem that does not require the use of additional supports along thewidth of the conveyor belt.

Moreover, it is noted that while many implementations and embodiments ofa conveyor belt interacting with a block chain in conjunction with thedrum assembly are presented herein and described as the block chainhelically wrapping around a drum assembly along an inner edge of theconveyor belt, it is also noted that such interaction may be along anouter edge of the conveyor belt. That is to say, such an appropriatelyimplemented outer edge stacker may be implemented without departing fromthe scope and spirit of the invention. For example, the mechanicalinteraction of the block chain with the drum assembly may instead be onthe opposite lengthwise edge of the conveyor belt in comparison to manyof the implementations and embodiments described herein.

Generally speaking, as also may be understood with respect to variousembodiments and implementations herein, engagement of a conveyor beltwithin such a novel system as presented herein may be viewed as beingperformed in a number of different ways including via compression, viamechanical engagement, via a combination of compression and mechanicalengagement, etc.

A variety of different embodiments of block chains, respective linksthereof, etc. have been presented herein. Generally speaking, anydesired such embodiment of block chain, links thereof, etc., such as inaccordance with various aspects, and their equivalents, of theinvention, may be employed within any desired conveyor belt systemincluding a spiral conveyor belt system.

It is again noted that while at least one preferred embodiment isimplemented in accordance with a spiral conveyor belt system, variousaspects, and their equivalents, of the invention may be generallyapplied to any of a wide variety of types of conveyor belt systems. Forexample, within a non-spiral conveyor belt system, a particular portionof such an overall conveyor belt system may be implemented such that ablock chain may be in continuous contact with at least a portion of aconveyor belt above and/or below for effectuating direct engagement ofthe conveyor belt and driving the conveyor belt through the overallconveyor belt system. One such possible implementation by which suchcontinuous contact between a block chain and at least a portion of aconveyor belt may be made is in accordance with a spiral conveyor beltsystem, though it is again noted that such in accordance with aspects,and their equivalents, of the invention may be generally applied to anyof a wide variety of types of conveyor belt systems.

Also, it is noted that while various diagrams and/or embodiments hereinare directed towards the description of as few as one conveyor beltsystem which may include as few as one spiral conveyor portion thereof,it is noted that a given conveyor belt system may include multiplespiral conveyor portions therein. For example, a singular conveyor beltsystem may include more than one spiral conveyor portion therein, suchthat each respective spiral conveyor portion may be particularly adaptedand tailored for different respective processing, such as with respectto other various aspects, and their equivalents, of the inventionincluding those as described with reference to FIG. 2. Alternatively,multiple respective conveyor belt systems may also be implemented andcooperatively operative with one another, such that product istransported at one or more appropriate locations from one conveyor beltsystem to another within an overall multi-conveyor belt system design.Any one or more of the respective conveyor belt systems within such anoverall multi-conveyor belt system design may include one or more spiralconveyor portions therein.

As may be used herein, the terms “substantially” and “approximately”provide an industry-accepted tolerance for its corresponding term and/orrelativity between items. Such an industry-accepted tolerance rangesfrom less than one percent to fifty percent. Such relativity betweenitems ranges from a difference of a few percent to magnitudedifferences.

The present invention has been described herein, at least in part, withthe aid of method steps illustrating the performance of specifiedfunctions and relationships thereof. The boundaries and sequence ofthese functional building blocks and method steps have been arbitrarilydefined herein for convenience of description. Alternate boundaries andsequences can be defined so long as the specified functions andrelationships are appropriately performed. Any such alternate boundariesor sequences are thus within the scope and spirit of the claimedinvention. Further, the boundaries of these functional building blockshave been arbitrarily defined for convenience of description. Alternateboundaries could be defined as long as the certain significant functionsare appropriately performed. Similarly, flow diagram blocks may alsohave been arbitrarily defined herein to illustrate certain significantfunctionality. To the extent used, the flow diagram block boundaries andsequence could have been defined otherwise and still perform the certainsignificant functionality. Such alternate definitions of both functionalbuilding blocks and flow diagram blocks and sequences are thus withinthe scope and spirit of the claimed invention. One of average skill inthe art will also recognize that the functional building blocks, andother illustrative blocks, and components herein, can be implemented asillustrated or alternatively to effectuate corresponding operationthereof.

The present invention may have also been described, at least in part, interms of one or more embodiments. An embodiment of the present inventionis used herein to illustrate the present invention, an aspect thereof, afeature thereof, a concept thereof, and/or an example thereof. Aphysical embodiment of an apparatus, an article of manufacture, amachine, and/or of a process that embodies the present invention mayinclude one or more of the aspects, features, concepts, examples, etc.described with reference to one or more of the embodiments discussedherein. Further, from figure to figure, the embodiments may incorporatethe same or similarly named functions, steps, modules, etc. that may usethe same or different reference numbers and, as such, the functions,steps, modules, etc. may be the same or similar functions, steps,modules, etc. or different ones.

While particular combinations of various functions and features of thepresent invention have been expressly described herein, othercombinations of these features and functions are likewise possible. Thepresent invention is not limited by the particular examples disclosedherein and expressly incorporates these other combinations.

What is claimed is:
 1. A conveyor belt system comprising: a drumassembly that includes a plurality of drum bars; a block chainconfigured to engage at least one of the plurality of drum bars and tobe driven by the drum assembly when the drum assembly rotates, whereinthe block chain is fabricated of a material having ability to operatewithin an environment that is affected by at least one of heating,cooling, drying, freezing, or airflow, wherein the block chain includesa plurality of links, wherein at least one of the plurality of links hasa hook or protrusion located on a backside of the at least one of theplurality of links configured to engage mechanically with at least oneof the plurality of drum bars directly so that the block chain is drivenby the drum assembly when the drum assembly rotates, wherein the atleast one of the plurality of links has a first tab on a top thereof anda second tab on a bottom thereof such that the first tab and the secondtab are configured to prevent at least one portion of a conveyor beltfrom contacting at least one of the plurality of drum bars of the drumassembly; and the conveyor belt configured to be driven in at least onedirection when in continuous mechanical engagement lengthwise with atleast one portion of the block chain when the block chain engages the atleast one of the plurality of drum bars and is driven by the drumassembly.
 2. The conveyor belt system of claim 1, wherein the blockchain is fabricated of at least one of polyethylene material, ultrahighmolecular weight (UHMW) plastic, or food grade nonporous plastic.
 3. Theconveyor belt system of claim 1, wherein the block chain is furtherconfigured to: drive the conveyor belt through a first processing regionfor heating; and drive the conveyor belt through a second processingregion for at least one of cooling or freezing.
 4. The conveyor beltsystem of claim 1, wherein an inner edge of the conveyor belt is engagedwith the block chain based on a clamping force between stacking pointsof the block chain.
 5. The conveyor belt system of claim 1 furthercomprising: a motor configured to rotate the drum assembly.
 6. Theconveyor belt system of claim 1, wherein the conveyor belt is furtherconfigured to: be driven spirally or helically upward or downward aroundthe drum assembly when the block chain engages the at least one of theplurality of drum bars and when the block chain is driven by the drumassembly.
 7. The conveyor belt system of claim 1, wherein the conveyorbelt is further configured to: be driven in the at least one directionwhen compressed from above by a first portion of the block chain andfrom below by a second portion of the block chain when the block chainengages the at least one of the plurality of drum bars and drives thedrum assembly rotationally.
 8. The conveyor belt system of claim 1,wherein the block chain and the conveyor belt are alternatively andvertically stacked, and the conveyor belt includes a plurality ofintegrated supports implemented along at least one portion of theconveyor belt and configured to maintain separation between stackedlayers of the conveyor belt.
 9. A conveyor belt system comprising: adrum assembly that includes a plurality of drum bars; a motor configuredto rotate the drum assembly; a block chain configured to engage at leastone of the plurality of drum bars and to be driven by the drum assemblywhen the drum assembly is rotated by the motor, wherein: the block chainis fabricated of a material having ability to operate within anenvironment that is affected by at least one of heating, cooling,drying, freezing, or airflow; the block chain including a plurality oflinks, wherein at least one of the plurality of links has a first tab ona top thereof and a second tab on a bottom thereof such that the firsttab and the second tab are configured to prevent at least one portion ofa conveyor belt from contacting at least one of the plurality of drumbars of the drum assembly; and at least one of the plurality of linkshas a hook or protrusion configured to engage mechanically with at leastone of the plurality of drum bars directly so that the block chain isdriven by the drum assembly when the drum assembly rotates; and theconveyor belt configured to be driven in at least one direction when incontinuous mechanical engagement lengthwise with at least one portion ofthe block chain when the block chain engages the at least one of theplurality of drum bars and is driven by the drum assembly.
 10. Theconveyor belt system of claim 9, wherein the block chain is fabricatedof at least one of polyethylene material, ultrahigh molecular weight(UHMW) plastic, or food grade nonporous plastic.
 11. The conveyor beltsystem of claim 9, wherein the block chain is further configured to:drive the conveyor belt through a first processing region for heating;and drive the conveyor belt through a second processing region for atleast one of cooling or freezing.
 12. The conveyor belt system of claim9, wherein the hook or protrusion of the at least one of the pluralityof links is located on a backside of the at least one of the pluralityof links.
 13. The conveyor belt system of claim 9, wherein the conveyorbelt is further configured to: be driven spirally or helically upward ordownward around the drum assembly when the block chain engages the atleast one of the plurality of drum bars and when the block chain isdriven by the drum assembly.
 14. A method for execution by a conveyorbelt system, the method comprising: rotating a drum assembly thatincludes a plurality of drum bars; engaging at least one of theplurality of drum bars by a block chain to drive the block chain by thedrum assembly when the drum assembly rotates, wherein the block chain isfabricated of a material having ability to operate within an environmentthat is affected by at least one of heating, cooling, drying, freezing,or airflow, wherein the block chain includes a plurality of links,wherein at least one of the plurality of links has a hook or protrusionlocated on a backside of the at least one of the plurality of linksconfigured to engage mechanically with at least one of the plurality ofdrum bars directly so that the block chain is driven by the drumassembly when the drum assembly rotates, the at least one of theplurality of links has a first tab on a top thereof and a second tab ona bottom thereof such that the first tab and the second tab areconfigured to prevent at least one portion of a conveyor belt fromcontacting at least one of the plurality of drum bars of the drumassembly; and driving the conveyor belt in at least one direction whenthe conveyor belt is in continuous mechanical engagement lengthwise withat least one portion of the block chain and when the block chain engagesthe at least one of the plurality of drum bars and is driven by the drumassembly.
 15. The method of claim 14, wherein the block chain isfabricated of at least one of polyethylene material, ultrahigh molecularweight (UHMW) plastic, or food grade nonporous plastic.
 16. The methodof claim 14 further comprising: driving the conveyor belt through afirst processing region for heating; and driving the conveyor beltthrough a second processing region for at least one of cooling orfreezing.
 17. The method of claim 14, further comprising engaging aninner edge of the conveyor belt with the block chain based on a clampingforce between stacking points of the block chain.
 18. The method ofclaim 14 further comprising: operating a motor configured to rotate thedrum assembly.
 19. The method of claim 14 further comprising: drivingthe conveyor belt spirally or helically upward or downward around thedrum assembly when the block chain engages the at least one of theplurality of drum bars and when the block chain is driven by the drumassembly.
 20. The method of claim 14 further comprising: driving theconveyor belt in the at least one direction when compressed from aboveby a first portion of the block chain and from below by a second portionof the block chain when the block chain engages the at least one of theplurality of drum bars and drives the drum assembly.